M-16-35 REV NOVEMBER 2017 - Maxon Lift...14 Combined EXXON & MOBIL oils on the same row with updated...

© 2017 MAXON LIFT CORP.

M-16-35REV B NOVEMBER 2017

LIFT CORP.

11921 Slauson Ave.Santa Fe Springs, CA. 90670

CUSTOMER SERVICE: TELEPHONE (562) 464-0099 TOLL FREE (800) 227-4116

FAX: (888) 771-7713

WARRANTY/ RMA POLICY & PROCEDURE

NOTE: For latest version of all Manuals (and replacements), download theManuals from Maxon’s website at www.maxonlift.com.

LIFTGATE WARRANTY

Type of Warranty: Full Parts and Labor

Term of Warranty: Standard Liftgates - 2 years from ship date or 6,000 cyclesPremium Liftgates - 2 years from ship date or 10,000 cycles

This warranty shall not apply unless the product is installed, operated and maintained in accordance with MAXON Lift’s specifi cations as set forth in MAXON Lift’s Installation, Operation and Maintenance manuals. This warranty does not cover normal wear, maintenance or adjustments, damage or malfunction caused by improper handling, installation, abuse, misuse, negligence, or carelessness of operation. In addition, this warranty does not cover equipment that has had unauthorized modifi cations or alterations made to the product.

MAXON agrees to replace any components which are found to be defective during the fi rst 2 years of service, and will reimburse for labor based on MAXON’s Liftgate Warranty Flat Rate Schedule. (Copy of the Flat Rate is available at www.maxonlift.com.)

All warranty repairs must be performed by an authorized MAXON warranty facility. For any repairs that may exceed $500, including parts and labor, MAXON’s Technical Service Department must be notifi ed and an “Authorization Number” obtained.

All claims for warranty must be received within 30 Days of the repair date, and include the following information:

1. Liftgate Model Number and Serial Number2. The End User must be referenced on the claim3. Detailed Description of Problem4. Corrective Action Taken, and Date of Repair5. Parts used for Repair, Including MAXON Part Number(s)6. MAXON R.M.A. # and/or Authorization # if applicable (see below)7. Person contacted at MAXON if applicable8. Claim must show detailed information i.e. Labor rate and hours of work performed

Warranty claims can also be placed online at www.maxonlift.com. Online claims will be given priority processing.

All claims for warranty will be denied if paperwork has not been received or claim submitted via Maxon website for processing by MAXON’s Warranty Department within 30 days of repair date.

All components may be subject to return for inspection, prior to the claim being processed. MAXON products may not be returned without prior written approval from MAXON’s Technical Service Department. Returns must be accompanied by a copy of the original invoice or reference with original invoice number and are subject to a credit deduction to cover handling charges and any necessary reconditioning costs. Unauthorized returns will be refused and will become the responsibility of the returnee.

Any goods being returned to MAXON Lift must be pre-approved for return, and have the R.M.A. number written on the outside of the package in plain view, and returned freight prepaid. All returns are subject to a 15% handling charge if not accompanied by a detailed packing list. Returned parts are subject to no credit and returned back to the customer. Defective parts requested for return must be returned within 30 days of the claim date for consideration to:

MAXON Lift Corp.10321 Greenleaf Ave., Santa Fe Springs, CA 90670

Attn: RMA#__

MAXON’s warranty policy does not include the reimbursement for travel time, towing, vehicle rental, service calls, oil, batteries or loss of income due to downtime. Fabrication or use of non Maxon parts, which are available from MAXON, are also not covered.

MAXON’s Flat Rate Labor Schedule takes into consideration the time required for diagnosis of a problem.

All Liftgates returned are subject to inspection and a 15% restocking fee. Any returned Liftgates or components that have been installed or not returned in new condition will be subject to an additional reworking charge, which will be based upon the labor and material cost required to return the Liftgate or component to new condition.

PURCHASE PART WARRANTY

Term of Warranty: 1 Year from Date of Purchase.

Type of Warranty: Part replacement only. MAXON will guarantee all returned genuine MAXON replacement parts upon receipt and inspection of parts and original invoice.All warranty replacements parts will be sent out via ground freight. If a rush shipment is requested, all freight charges will be billed to the requesting party.

TABLE OF CONTENTS

SUMMARY OF CHANGES: M-16-35, REVISION B ............................................................. 6

WARNINGS ........................................................................................................................... 7

SAFETY INSTRUCTIONS .................................................................................................... 8

LIFTGATE TERMINOLOGY .................................................................................................. 9

PERIODIC MAINTENANCE ................................................................................................ 10

PERIODIC MAINTENANCE CHECKS ................................................................................ 10

PERIODIC MAINTENANCE CHECKLIST ............................................................................11

CHECKING HYDRAULIC FLUID ........................................................................................ 13

CHANGING HYDRAULIC FLUID ........................................................................................ 15

PLATFORM ADJUSTMENT ................................................................................................ 18

REPLACING PLATFORM TORSION SPRING ................................................................... 21

SAFETY HOOK MAINTENANCE ........................................................................................ 23

DECALS & PLATES ........................................................................................................... 24

PUMP, MOTOR & SOLENOID OPERATION - GRAVITY DOWN ....................................... 26

PUMP, MOTOR & SOLENOID OPERATION - POWER DOWN ......................................... 27

HYDRAULIC SYSTEM DIAGRAMS ................................................................................... 28

HYDRAULIC SCHEMATIC (GRAVITY DOWN) ................................................................... 28

HYDRAULIC SCHEMATIC (POWER DOWN) .................................................................... 29

ELECTRICAL SYSTEM DIAGRAMS ................................................................................. 30

ELECTRICAL SCHEMATIC (GRAVITY DOWN) ................................................................. 30

ELECTRICAL SCHEMATIC (POWER DOWN) ................................................................... 31

TE SERIES ELECTRICAL VALUES .................................................................................... 32

TROUBLESHOOTING ........................................................................................................ 33

PLATFORM WILL NOT RAISE ............................................................................................ 33

PLATFORM RAISES BUT LEAKS DOWN .......................................................................... 34

PLATFORM RAISES PARTIALLY AND STOPS .................................................................. 35

LIFTGATE WILL NOT LIFT RATED CAPACITY .................................................................. 36

PLATFORM RAISES SLOWLY ........................................................................................... 37

PLATFORM WILL NOT LOWER, LOWERS TOO SLOWLY OR TOO QUICKLY ................ 38

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SUMMARY OF CHANGES: M-16-35, REVISION BPAGE DESCRIPTION OF CHANGE

Cover Includes TE-15 and TE-20 liftgates.

14 Combined EXXON & MOBIL oils on the same row with updated part numbers.

29 Updated power down hydraulic schematic shows solenoid valves S1 & S2.

30, 31 Gravity down and power down electrical schematics are updated to same level of details as installation manual.

32 Added TE Series electrical values.

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WARNINGS• Do not stand, or allow obstructions, under the platform when lowering the Liftgate. Be sure your

feet are clear of the Liftgate.

• Keep fi ngers, hands, arms, legs, and feet clear of moving Liftgate parts (and platform edges) when operating the Liftgate.

• Disconnect Liftgate power cable from battery before repairing or servicing Liftgate.

Comply with the following WARNINGS and SAFETY INSTRUCTIONS while maintaining Liftgates. See Operation Manual for operating safety requirements.

• If it is necessary to stand on the platform while maintaining the Liftgate, keep your feet and any objects clear of the inboard edge of the platform. Your feet or objects on the platform can become trapped between the platform and the Liftgate extension plate.

WARNING!

• Correctly stow platform when not in use. Extended platforms could create a hazard for people and vehicles passing by.

• Recommended practices for welding on steel parts are contained in the current AWS (American Welding Society) D1.1 Structural Welding Code - Steel. Damage to Liftgate and/or vehicle, and personal injury could result from welds that are done incorrectly.

• Recommended practices for welding on aluminum parts are contained in the current AWS (American Welding Society) D1.2 Structural Welding Code - Aluminum. Damage to Liftgate and/or vehicle, and personal injury could result from welds that are done incorrectly.

• Recommended practices for welding galvanized steel are contained in the current AWS (Ameri-can Welding Society) D19.0 Welding Zinc-Coated Steel. Damage to Liftgate and/or vehicle,

and personal injury can result from welds that are done incorrectly.


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SAFETY INSTRUCTIONS

• Keep decals clean and legible. If decals are illegible or missing, replace them. Free replacement decals are available from Maxon Customer Service.

• Consider the safety and location of bystanders and location of nearby objects when operating the Liftgate. Stand to one side of the platform while operating the Liftgate.

• Wear appropriate safety equipment such as protective eyeglasses, faceshield and clothing while performing maintenance on the Liftgate and handling the battery. Debris from drilling and contact with battery acid may injure unprotected eyes and skin.

• Do not allow untrained persons to operate the Liftgate.

• Be careful working by an automotive type battery. Make sure the work area is well ventilated and there are no fl ames or sparks near the battery. Never lay objects on the battery that can short the terminals together. If battery acid gets in your eyes, immediately seek fi rst aid. If acid gets on your skin, immediately wash it off with soap and water.

• If an emergency situation arises (vehicle or Liftgate) while operating the Liftgate, release the con-trol switch to stop the Liftgate.

• Read and understand the instructions in this Maintenance Manual before performing mainte-nance on the Liftgate.

• Before operating the Liftgate, read and understand the operating instructions in Operation Manual.

• Comply with all WARNING and instruction decals attached to the Liftgate.

• A correctly installed Liftgate operates smoothly and reasonably quiet. The only noticeable noise during operation comes from the power unit while the platform is raised. Listen for scraping, grat-ing and binding noises and correct the problem before continuing to operate Liftgate.

• Use only Maxon Authorized Parts for replacement parts. Provide Liftgate model and serial num-ber information with your parts order. Order replacement parts from:

MAXON LIFT CORP. Customer Service 11921 Slauson Ave., Santa Fe Springs, CA 90670

Online: www.maxonlift.com Express Parts Ordering: Phone (800) 227-4116 ext. 4345 Email: Ask your Customer Service representative

SAFETY INSTRUCTIONS

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LIFTGATE TERMINOLOGY

LIFT FRAME

CONTROL SWITCH

PARALLEL ARM

PLATFORM

LIFTCYLINDER

EXTENSION PLATE

FLEX STEP

PUMP BOX(COVER SHOWN)

MAIN FRAME

WEDGE FLIPOVER

PLATFORM OPENER

TORSION SPRINGS

DOCKBUMPER


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PERIODIC MAINTENANCEPERIODIC MAINTENANCE CHECKS

Never operate the Liftgate if parts are loose or missing.WARNING

NOTE: Make sure vehicle is parked on level ground while performing the maintenance checks.

Quarterly or 1250 Cycles (whichever occurs fi rst)

Semi-annually or 2500 Cycles (whichever occurs fi rst) Visually check the platform hinge pins for excessive wear and broken welds. See PARTS BREAKDOWN section for replacement parts. Also, do the Quarterly or 1250 Cycles maintenance checks.

Check the hydraulic fl uid level in the pump reservoir. Refer to the CHECKING HYDRAULIC FLUID procedure in the PERIODIC MAINTENANCE section.

If hydraulic fl uid appears contaminated, refer to the CHANGING HYDRAULIC FLUID procedure in the PERIODIC MAINTENANCE section.

Keep track of the grade of hydraulic fl uid in the pump reservoir and never mix two different grades of fl uid.

Check all hoses and fi ttings for chafi ng and fl uid leaks. Tighten loose fi ttings or replace parts as required.

Check electrical wiring for chafi ng and make sure wiring connections are tight and free of corrosion. Use dielectric grease to protect electrical connections.

Check that all WARNING and instruction decals are in place. Also, make sure decals are legible, clean and undamaged.

Check that all bolts, nuts, and roll pins are in place. Make sure roll pins protrude evenly from both sides of hinge pin collar. Replace fasteners and roll pins if necessary.

!

Check for rust and oily surfaces on Liftgate. If there is rust or oil on Liftgate, clean it off. Touch up the paint or galvanized fi nish where bare metal is showing. MAXON recommends using the aluminum primer touchup paint or cold galvanize spray for galvanized fi nish.

Damaged cylinder seals and contaminated hydraulic fl uid can result from paint-ing the polished portion of the cylinder rod. To prevent damage, protect the exposed polished portion of the cylinder rod while painting.

CAUTION

Pump EP chassis grease in each lube fi tting on the cylinders and arms until grease starts oozing from ends of the bearings. The lubrication diagram on the PERIODIC MAINTENANCE CHECKLIST SHEET shows where to fi nd the lube fi ttings. Wipe off excess grease with a clean lint-free cloth.

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PERIODIC MAINTENANCE CHECKLISTNOTE: Make sure vehicle is parked on level ground while performing the

maintenance checks.

Quarterly or 1250 Cycles (whichever occurs fi rst)

Semi-annually or 2500 Cycles (whichever occurs fi rst)

Check the level and condition of the hydraulic fl uid.

Check that all WARNING and instruction decals are in place. Also, make sure decals are legible and decals are clean and undamaged.

Check that all bolts, nuts, and roll pins are in place. Make sure roll pins protrude evenly from both sides of hinge pin collar. Replace fasteners and roll pins if necessary.

Visually check the platform hinge pins for excessive wear and broken welds.

Do the Quarterly or 1250 Cycles Checks on this checklist.

Check for rust and oily surfaces on Liftgate. If there is rust or oil on Liftgate or if the Lift-gate is dirty, clean it off. Touch up the paint or galvanized fi nish where bare metal is showing. To maintain the protection provided by the original paint system or galvanized fi nish, MAXON recommends using the aluminum primer touchup paint or cold galvanize spray for galvanized fi nish.

Check electrical wiring for chafi ng and make sure wiring connections are tight and free of corrosion. Use dielectric grease to protect electrical connections.

Visually check all hoses for chafi ng and fl uid leaks. Tighten loose fi ttings or replace parts as required.

Damaged cylinder seals and contaminated hydraulic fl uid can result from painting the polished portion of the cylinder rod. To prevent damage,protect the exposed polished portion of the cylinder rod while painting.

CAUTION

Pump EP chassis grease in each lube fi tting on the cylinders and arms until grease starts oozing from ends of the bearings. Refer to lubrication diagram on the next page. Wipe off excess grease with a clean lint-free cloth.


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PERIODIC MAINTENANCEPERIODIC MAINTENANCE CHECKLIST - Continued

NOTE: Lube fi ttings are shown for the cylinder, LH lift arm, and LH parallelarm. There are also lube fi ttings at the same places on the RHcylinder, lift arm, and parallel arm.

LUBRICATION DIAGRAMFIG. 12-1

RH LIFT ARM &PARALLEL ARM

CYLINDER

LH LIFT ARM &PARALLEL ARM

Refer to lubrication diagram (FIG. 12-1) to fi nd the lube fi ttings on cylinders and arms. Pump EP chassis grease in each lube fi tting on the cylinders and arms until grease starts oozing from ends of the bearings. Then, wipe off excess grease with a clean lint-free cloth.

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CHECKING HYDRAULIC FLUID

1. With platform at bed height, check oil level in the pump reservoir (FIG. 13-1). To add oil, pull out fi ller cap (no threads) (FIG. 13-1). Add hydraulic oil in reservoir to the level shown in FIG. 13-1.

2. Reinstall fi ller cap (FIG. 13-1).

Keep dirt, water and other contaminants from entering the hydraulic system. Before opening the hydraulic fl uid reservoir fi ller cap, drain plug and hydrau-lic lines, clean up contaminants that can get in the openings. Also, protect the openings from accidental contamination.

FILLER CAP

RESERVOIR

PUMP RESERVOIR(GRAVITY DOWN POWER UNIT SHOWN)

FIG. 13-1

1-7/8” - 2-3/8” (GD)2-5/8” - 3-1/8” (PD)

3. Bolt on the pump cover as shown in FIG. 13-2. Torque the bolts (cap screws) to 10 - 14 lb-in.

BOLTING ON PUMP COVERFIG. 13-2

NOTE: Liftgate is shipped with ISO 32 oil. Use correct oil for climate conditions.

See TABLES 14-1 & 14-2 for recommended brands of ISO 32 & ISO 15 oils.

NOTE: Hydraulic oil level must be mini-mum of 1-1/2” above the bottom of reservoir to operate Liftgate.

POWER UNIT(REF)

PUMP COVER

CAP SCREWS

(5 PLACES)FLAT

WASHERS(5 PLACES)

PUMP MOUNTPLATE

CAUTION

+50 to +120 Degrees F - Grade ISO 32 Below + 70 Degrees F - Grade ISO 15 or MIL-H-5606


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PERIODIC MAINTENANCECHECKING HYDRAULIC FLUID - Continued

TABLE 14-2

TABLE 14-1

ISO 32 HYDRAULIC OIL

RECOMMENDED BRANDS PART NUMBER

CHEVRON HIPERSYN 32

KENDALL GOLDEN MV

SHELL TELLUS S2 VX 32

EXXONMOBIL UNIVIS N-32, DTE-24

ISO 15 OR MIL-H-5606 HYDRAULIC OIL

RECOMMENDED BRANDS PART NUMBER

CHEVRON FLUID A, AW-MV-15

KENDALL GLACIAL BLU

SHELL TELLUS S2 VX 15

EXXONMOBIL UNIVIS HVI-13

ROSEMEAD THS FLUID 17111

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CHANGING HYDRAULIC FLUID

3. Disconnect the white wire (FIG. 15-2) from starter solenoid. Lower the platform while draining the remaining hydraulic fl uid from system. Reinstall drain plug. Reconnect the white wire to starter solenoid.

2. Open and raise platform to vehicle bed height. Pull out (no threads) drain plug (FIG. 15-1). Drain hydraulic fl uid.

CAUTIONKeep dirt, water and other contaminants from entering the hydraulic system. Before opening the hydraulic fl uid reservoir fi ller cap, drain plug and hydrau-lic lines, clean up contaminants that can get in the openings. Also, protect the openings from accidental contamination.

POWER DOWN LIFTGATES1. Remove the pump cover (FIG. 13-1). Place empty

5 gallon bucket under drain plug (FIG. 15-1).

4. Pull out (no threads) fi ller cap (FIG. 15-1) and refi ll reservoir with hydraulic fl uid to level shown in FIG. 15-1. Reinstall fi ller cap (FIG. 15-1).

1. Remove the pump cover (FIG. 13-1). Place empty 5 gallon bucket under drain plug (FIG. 15-1).

GRAVITY DOWN LIFTGATES

2. Lower platform to ground. Pull out (no threads) drain plug (FIG. 15-1). Drain hydrau-lic fl uid from system. Reinstall drain plug.

3. Pull out (no threads) fi ller cap (FIG. 15-1) and refi ll reservoir with hydraulic fl uid to level shown in FIG. 15-1. Reinstall fi ller cap (FIG. 15-1).

4. Bolt on the pump cover as shown in FIG. 16-1 Torque the bolts (cap screws) to 10-14 lb-in. LIFTGATE SHOWN WITH GRAVITY

DOWN PUMP & MOTORFIG. 15-1

DRAIN PLUG

POWER DOWN PUMPFIG. 15-2

STARTER SOLENOID

WHITE WIRE

+50 to +120 Degrees F - Grade ISO 32 Below + 70 Degrees F - Grade ISO 15 or MIL-H-5606

NOTE: Liftgate is shipped with ISO 32 oil. Use correct oil for climate conditions.

See TABLES 14-1 & 14-2 for recommended brands of ISO 32 & ISO 15 oils.

FILLER CAP

RESERVOIR

1-7/8” - 2-3/8” (GD)2-5/8” - 3-1/8” (PD)


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PERIODIC MAINTENANCECHANGING HYDRAULIC OIL - Continued

5. Bolt on the pump cover as shown in FIG. 16-1. Torque the cap screws to 10-14 lb-in.

BOLTING PUMP COVERFIG. 16-1

POWER UNIT(REF)

PUMP COVER

CAP SCREWS

(5 PLACES)FLAT

WASHERS(5 PLACES)

PUMP MOUNTPLATE

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THIS PAGE INTENTIONALLY LEFT BLANKTHIS PAGE INTENTIONALLY LEFT BLANK


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PERIODIC MAINTENANCE

NOTE: Before doing the following procedure, make sure vehicle is parked on level ground.

PLATFORM ADJUSTMENT

“A” (TABLE 18-1)

PLATFORM EDGE ABOVE BED LEVEL

FIG. 18-2

SHACKLES DO NOT TOUCH GROUND FIG. 18-3A

PLATFORM & SHACKLES TOUCH GROUND

FIG. 18-1

2. Make sure platform is still at ground level. If the shackle is not touching the ground, mea-sure and compare distance “A” (FIG. 18-3A) with TABLE 18-1 to determine the correct shim. Next, mark position on shackle (FIG. 18-3B).

1. Make sure platform is at ground level. Unfold the platform and fl ipover. As the platform fi rst touches the ground, shackles and tip of fl ipover must touch the ground at the same time (FIG. 18-1). If the shackles and the tip of fl ipover touch the ground at the same time, raise plat-form to bed height. Outboard edge on top of fl ipover should be above bed level (FIG. 18-2). If indications are correct in both cases (FIGS. 18-1 & 18-2), Liftgate is installed correctly and no adjustment is needed. If indications are incorrect, continue with instruction 2.

LEVEL LINE

TIP OF FLIPOVER

OUTBOARDEDGE

RAISE TIP OF FLIPOVER

THIS DISTANCE “A”

REQUIRED SHIM THICKNESS

WELD

SIZE “W”

9/16” 1/16” 1/16”

1-1/4” 1/8” 1/8”

1-15/16” 3/16” 3/16”

2-5/8” 1/4” 1/4”

NOTE: If tip of fl ipover touches fi rst (FIG. 18-3A), do instructions 2 and 3. If the shackle touches fi rst (see FIG. 20-1), skip 2 and 3 and do instructions 4 and 5.

SHIMS TO RAISE TIP OF FLIPOVERTABLE 18-1

MARKING SHIM POSITION FIG. 18-3B

1/4”

SHACKLE

PLATFORM STOP

MARK HERE

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2 PLACES“W”

(TABLE 18-1)

SHIM(TABLE 18-1 )

SHACKLE(REF)

CENTERED

WELDING SHIMS (RH SHACKLE SHOWN)FIG. 19-2

SHIM (1/16”, 1/8”, 3/16”, or 1/4”) MADE FROM STEEL FLAT

FIG. 19-1

2-1/4”

1-1/2”

3. Make shims as needed (FIG. 19-1). Posi-tion bottom edge of shim to line up with mark on shackle (FIG. 19-2). Then, weld the shim to shackle as shown in FIG. 19-2.


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PERIODIC MAINTENANCEPLATFORM ADJUSTMENT - Continued

4. Make sure platform is still at ground level. If the tip of fl ipover is not touching the ground, measure and compare distance “B” (FIG. 20-1) with TABLE 20-1 to determine how much to grind from the platform stops (FIG. 20-2).

6. Raise the platform, then lower it to the ground. As the platform fi rst touches the ground, the tip of fl ipover and shackle should touch at the same time as shown in FIG. 20-3.

LOWER TIP OF FLIPOVER

THIS DISTANCE “B”

GRIND METAL FROM PLATFORM STOP

9/16” 1/16”

1-1/4” 1/8”

1-15/16” 3/16”

2-5/8” 1/4”

GRIND TO LOWER TIP TABLE 20-1

5. Grind correct amount of metal (TABLE 20-1) from platform stop as shown in FIG. 20-2.

GRINDING PLATFORM STOPS (RH SHACKLE SHOWN)

FIG. 20-2

PLATFORM

SHACKLE(REF)

PLATFORMSTOP

GRIND ENTIRE SURFACE HERE

(TABLE 20-1)

PLATFORM & SHACKLES TOUCH GROUND

FIG. 20-3

TIP OF FLIPOVER

SHACKLE

“B” (TABLE 20-1)

TIP OF FLIPOVER DOES NOTTOUCH GROUND

FIG. 20-1

TIP OF FLIPOVER

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REPLACING PLATFORM TORSION SPRING

1. Fold fl ipover onto platform.

4. Remove cap screw, fl at washer and locknut from pin collar on the platform hinge bracket. Drive the platform hinge pin outboard from the shackle just enough to free the torsion spring (FIG. 21-1). Remove torsion spring.

5. Install the torsion spring as shown in (FIG. 21-2). Make sure the long leg of the spring is inserted through the hole in the block on the shackle (FIG. 21-2). Make sure the short end of the spring is positioned as shown in FIG. 21-2.

3. Raise Liftgate to a convenient work height to gain access and release tension on the torsion spring.

2. Fold platform.

To prevent injury and equipment dam-age, make sure there is no tension on torsion spring before removing hinge pin.

CAUTION!

FIG. 21-2

LONG LEG

PLATFORM HINGE

BRACKET

BLOCK

SHACKLE

SHORT LEG

FIG. 21-1

SHACKLE

PLATFORM HINGE PIN

CAP SCREW

LOCK NUT

FLAT WASHER

TORSION SPRING

PIN COLLAR


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PERIODIC MAINTENANCE

6. Drive platform hinge pin inboard to correct position through the platform hinge bracket (FIG. 22-1). Line up the hole in the platform hinge pin with the hole in the pin collar. Reinstall cap screw through the pin collar and secure with fl at washer and locknut (FIG. 22-1).

REPLACING PLATFORM TORSION SPRING - Continued

PINCOLLAR

FIG. 22-1

CAPSCREW

FLAT WASHERLOCK

NUT

PLATFORM HINGE BRACKET

PLATFORM HINGE PIN

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SAFETY HOOK MAINTENANCE

CHECK SAFETY HOOK FUNCTION

LOOP ADJUSTMENT

PLATFORM LOOP SHOWN HOOKED IN CORRECT POSITION

FIG. 23-1

1. When raising platform to stowed position, listen for sound of safety hook engaging platform loop.

2. When the Liftgate is stowed, see if plat-form loop is seated in the safety hook as shown in FIG. 23-1.

EXTENSIONPLATE

SAFETY HOOK

PLATFORM LOOP(CORRECT POSITION)

PLATFORM LOOP SHOWN HOOKED INCORRECTLY

FIG. 23-2

PLATFORM LOOP(CORRECT POSITION)

PLATFORM LOOP(INCORRECT POSITION)

1. If the safety hook is not positioned correctly (FIG. 23-2), lower platform enough to access the safety hook. (See Operation Manual for instructions to lower the platform.)

2. Adjust by bending the platform loop so it seats correctly in the hook as shown in FIG. 23-2.

3. Stow the platform and check for correct safety hook position (FIG. 23-2). Re-peat adjustment if required.


A. 90670 (800) 227-4116 FA

X (888) 771-7713

24

DECALS & PLATESNOTE: Ensure there is no residue, dirt or corrosion where decals are attached.

If necessary, clean surface before attaching decals.

NOTE: Preferred decal layout is shown, Decals on the Liftgate are attached at the factory. If vehicle does not permit this layout, decals in the manual and decal kit must be applied so that they are easily visible when approaching vehicle to operate Liftgate. Use good common sense when locating these decals on vehicle.

CAPACITY DECAL(REFER TO TABLE 25-1)

STOW WARNING DECAL P/N 282847-02

FIG. 24-1

DECAL “A”

DECAL “F”

DECAL “C”

DECAL “B”

WARNING DECALWARNING DECALP/N 265736-03P/N 265736-03

INSTRUCTION DECALINSTRUCTION DECALP/N 285800-01P/N 285800-01

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25

DECAL SHEET P/N 282522-01FIG. 25-1

CAPACITY DECALSTABLE 25-1

MODEL DECAL P/N CAPACITY TE-15 220386 1500 POUNDS [680 KG]TE-20 220387 2000 POUNDS [907 KG]TE-25 220382 2500 POUNDS [1134 KG]TE-30 220388 3000 POUNDS [1360 KG]


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X (888) 771-7713

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PUMP, MOTOR & SOLENOID OPERATION - GRAVITY DOWN

JUNCTION BLOCK

SOLENOID SWITCH

SOLENOID VALVE

SYSTEM DIAGRAMS

TABLE 26-1

GRAVITY DOWN PUMP MOTOR & SOLENOID SWITCH OPERATION

LIFTGATE FUNCTION

PORT

SOLENOID SWITCH OPERATION ( MEANS ENERGIZED)

MOTOR SOLENOID VALVE

RAISE PRESSURE -

LOWER VENT -

REFER TO VALVES SHOWN ON HYDRAULIC SCHEMATIC

MOTOR

PRESSURE

VENT

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771

-771

3

27

PUMP, MOTOR & SOLENOID OPERATION - POWER DOWN

POWER DOWN MODULE

TABLE 27-1

POWER DOWN PUMP MOTOR & SOLENOID SWITCH OPERATION

LIFTGATE FUNCTION

PORT

SOLENOID SWITCH OPERATION ( MEANS ENERGIZED)

MOTORVALVE “S2”

VALVE “S1”

POWER DOWN MODULE

RAISE A - -

LOWER B -

REFER TO VALVES SHOWN ON HYDRAULIC SCHEMATIC

MOTOR

PORT A

PORT B

“S2” VALVE

“S1” VALVE

SOLENOID SWITCH


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HYDRAULIC SYSTEM DIAGRAMSHYDRAULIC SCHEMATIC (GRAVITY DOWN)

FIG. 28-1FIG. 28-1

2 GPM FLOW CONTROL VALVE

VALVE A

HYDRAULIC CYLINDER

RELIEF VALVE(SET AT 3250 PSI)

PUMP MOTOR (REFERENCE)

VENT PORT

RESERVOIR

M

PRESSURE PORT

CHECK VALVE

FILTER

DRAIN HOLE(PLUGGED)

FILLER HOLE(PLUGGED)

AUX. HANDPUMP PORT(PLUGGED)

RETURN PORT(PLUGGED)

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29

HYDRAULIC SCHEMATIC (POWER DOWN)

PORT B - LOWER (POWER DOWN) PORT A - RAISE

RELIEF VALVE 2(SET AT 1100 PSI)

PUMP

AUX. HANDPUMP PORT (PLUGGED)

S1

HYDRAULIC CYLINDER

2 GPM FLOW CONTROL

VALVE

RESERVOIR

DRAIN HOLE(PLUGGED)

FILTER

MOTOR(REF)

RELIEF VALVE 1(SET AT 3250 PSI)

S2

FIG. 29-1FIG. 29-1


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ELECTRICAL SYSTEM DIAGRAMSELECTRICAL SCHEMATIC (GRAVITY DOWN)

FIG. 30-1

(DOWN)(UP)

CONTROL SWITCH

STARTERSOLENOID

MOTOR

FUSE HOLDER WITH 10 AMP

FUSE

SOLENOID VALVE

JUNCTION BLOCK

WHITE

BLACKGREEN

1

1

2

2CYCLE

COUNTER(IF

EQUIPPED)

BATTERY

CABLE WITH175 A FUSE

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31

ELECTRICAL SCHEMATIC (POWER DOWN)

FIG. 31-1

STARTER SOLENOID

WHITE

WHITE(CABLE)

BLACK(CABLE)

BLACK

BLACK

GREEN

RED

RED

1

2

13

3 42

5K1

1

2

SOLENOID, VALVE S2

SOLENOID, VALVE S1

(DOWN)(UP)

CONTROL SWITCH

POWER DOWN MODULE

BATTERY

MOTOR

FUSE HOLDER WITH 10 AMP

FUSE

CYCLE COUNTER(IF EQUIPPED)

1 2CABLE WITH 175 A FUSE


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TE SERIES ELECTRICAL VALUESSYSTEM DIAGRAMS

Solenoid Switch 12V 24V

Coil Resistance: 5.4Ω @70ºF. ±15% 20.1Ω @70ºF. ±15%

Ampere: 2.2A 1.2A

Coil terminal torque: 10-15 lb-in max.

Contact terminal torque: 30-35 lb-in max.

Solenoid Valves (A, S1, & S2)

Coil Resistance: 6.6Ω @ 70ºF. ±15% 26.7Ω @ 70ºF. ±15%

Ampere: 1.8A 0.9A

Coil terminal torque: 15-45 lb-in max.

Valve cartridge torque: 25-30 lb-ft max.

Coil nut torque: 15-45 lb-in

Solenoid Lock Valve

Coil Resistance: 8.0Ω @ 70ºF. ±15% 30Ω @ 70ºF. ±15%

Ampere: 1.5A 0.8A

Coil terminal torque: 3-4.5 lb-ft max.

Valve cartridge torque: 18.5-22 lb-ft max.

Ground Cable

Cap Screw Torque: 24 lb-ft max.

TABLE 32-1

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33

PLATFORM WILL NOT RAISE

1. Use voltmeter to verify power is being supplied to solenoid terminal “B” (FIG. 33-1). Recharge the battery if there is less than 12.6 volts.

5. Check for structural damage and replace worn parts.

6. Check fi lter in the pump reservoir. Replace fi lter if necessary.

7. Check for dirty pump motor relief valve. Clean if necessary.

Replace any worn out relief valve parts.

2. See the CHECKING HYDRAULIC FLUID procedure. If necessary, add hydraulic fl uid.

3. Touch a jumper wire to terminals “B” & “D” (FIG. 33-1). If motor runs, check switch, switch connections, and white wire. Check and correct wiring connections or replace the switch.

4. Touch heavy jumper cables to terminals “A” & “B” (FIG. 33-1). a. If motor runs, replace the motor solenoid. b. If motor does not run, repair or replace the pump motor.

TROUBLESHOOTING

Keep dirt, water and other contaminants from entering the hydraulic system. Before opening the hydraulic fl uid reservoir fi ller cap, drain plug and hydraulic lines, clean up contaminants that can get in the openings. Also, protect the openings fromaccidental contamination during maintenance.

CAUTION

NOTE: In most cases, you can avoid having to manually bleed hydraulic system by correctly positioning Liftgate platform before disconnecting any lifting

cylinder high pressure hydraulic lines. The following procedure can save time and prevent accidental fl uid spills and hazards.

FIG. 33-1

STARTER SOLENOID

LOWERINGSOLENOID

TERMINAL “A”MOTOR (+)

TERMINAL “B”BATTERY (+) TERMINAL “C”

GROUND (-)

TERMINAL “D” SWITCHED

BATTERY (+)


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X (888) 771-7713

34

PLATFORM RAISES BUT LEAKS DOWN

1. Check if solenoid valves are constantly energized by touching a screwdriver to the top nut of the solenoid (FIG. 34-1). Try pulling the screwdriver away from the solenoid. If the solenoid nut attracts the screwdriver (magnetically) without pushing the toggle switch, the con-trol circuit is operating incorrectly. Check if toggle switch, wiring or coil are faulty.

COIL

FIG. 34-1


CAUTION

2. Check the valve stem by removing the coil assembly (Item 1, FIG. 34-2). With platform on ground, unscrew the valve stem (Item 2, FIG. 34-2) from the pump. Push on the plunger that is located inside the valve stem by insert-ing a small screwdriver blade in the end. If the plunger does not move freely, (approximately 1/8”) replace the valve stem. When reinstall-ing valve stem, torque hex nut to 30 in-lbs.

3. Check the hydraulic cylinder. With the platform on the ground, remove the hydraulic line from the vent/down port of the cylinder (FIG. 34-3). Raise the platform even with the bed. Allow pump motor to run two seconds more while you watch for hydraulic fl uid at the vent/down port. A few drops of hydraulic fl uid escaping the vent/down port is normal; however, if it streams from the vent/down port, piston seals are worn. Replace seals.

RAISE PORT

VENT/DOWN PORT

FIG. 34-3

FIG. 34-2

2

1/8”1

NOTE: In most cases, you can avoid having to manually bleed hydraulic system by correctly positioning Liftgate platform before disconnecting any lifting cyl-

inder high pressure hydraulic lines. The following procedure can save time and prevent accidental fl uid spills and hazards.

TROUBLESHOOTING

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35


2. Use voltmeter to verify the battery shows 12.6 volts or more.

3. Check for structural damage and poor lubrication. Replace worn parts.

4. Check the hydraulic cylinder. With the platform on the ground, remove the breather plug or vent line from the vent/down port of the cylinder (FIG. 35-1). Raise the platform even with the bed. Allow pump motor to run two seconds more while you watch for hydraulic fl uid at the vent/down port. A few drops of hydraulic fl uid escaping the vent/down port is normal; however, if it streams from the vent/down port, piston seals are worn. Replace seals.

5. Check fi lter in the pump reservoir. Replace fi lter if necessary.

6. Check for dirty pump motor relief valve. Clean if necessary. Replace any worn out relief valve parts.

NOTE: In most cases, you can avoid having to bleed the hydraulic system bycorrectly positioning Liftgate platform before opening hydraulic lines. Refer to following procedure. Save time on the job and prevent accidental fl uid spills and hazards.


CAUTION

PLATFORM RAISES PARTIALLY AND STOPS

RAISE PORT

VENT/DOWN PORT

FIG. 35-1


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TROUBLESHOOTING

3. With platform on the ground, remove the pressure hose and fi tting from the pump and replace it with a 0-4000 PSI pressure gauge. Hold the switch in the “UP” position. Adjust the relief valve on the side of the pump until the gauge shows 3250 PSI (FIG. 36-2). Remove gauge and reinstall pressure hose.

4. Check for dirty pump motor relief valve. Clean if necessary. Replace any worn out relief valve parts.

5. Check the hydraulic cylinder. With the platform on the ground, remove the breather plug or vent line from the vent/down port of the cylinder (FIG. 36-1). Raise the platform even with the bed. Allow pump motor to run two seconds more while you watch for hydraulic fl uid at the vent/down port. A few drops of hydraulic fl uid escaping the vent/down port is normal; however, if it streams from the vent/down port, piston seals are worn. Re-place seals.

6. If pump cannot produce 3250 PSI, and will not lift load of rated capacity, the pump is worn and

needs to be replaced.

LIFTGATE WILL NOT LIFT RATED CAPACITY

1. Use voltmeter to verify the battery shows 12.6 volts or more under load from pumpmotor.

2. Check for structural damage and lack of lubrication. Replace worn parts.

FIG. 36-1

NOTE: In most cases, you can avoid having to bleed the hydraulic system by cor-rectly positioning Liftgate platform before opening hydraulic lines. Refer to following procedure. Save time on the job and prevent accidental fl uid spills and hazards.


CAUTION

PRESSUREGAUGE

RELIEF VALVE

ADJUST SCREW

(REMOVE PLUG)

FIG. 36-2

RAISE PORT

VENT/DOWN PORT

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37

PLATFORM RAISES SLOWLY

FLOW CONTROL

VALVE

VENT/DOWN PORT

PRESSURE PORT

FIG. 37-3

1. Use voltmeter to verify power is being supplied to solenoid terminal “B”. Recharge the battery if volt-meter indicates less than 12.6 volts (FIG. 37-1).

NOTE: In most cases, you can avoid having to bleed the hydraulic system bycorrectly positioning Liftgate platform before opening hydraulic lines. Refer to following procedure. Save time on the job and prevent accidental fl uid spills and hazards.

2. Check the hydraulic cylinder. With the platform on the ground, remove the breather plug or vent line from the vent/down port of the cylinder (FIG. 37-3). Raise the platform even with the bed. Allow pump motor to run two seconds more while you watch for hydraulic fl uid at the vent/down port. A few drops of hydraulic fl uid escaping the vent/down port is normal; however, if it streams from the vent/down port, piston seals are worn. Replace seals.

3. Check and clean fl ow control valve in high pressure hydraulic line attached to cylinder. When installing fl ow control valve, make sure arrow on valve is oriented as shown

in FIG. 37-3.


5. Verify the pump motor is grounded to the vehicle frame.

6. Check for leaking hoses and fi ttings. Tighten or replace as required.

7. Check for structural damage or poor lubrication. Replace worn parts.

8. Check the fi lter in the pump reservoir. Replace if neces-sary.

9. With platform on the ground, remove the pressure hose and fi tting from the pump and replace it with a 0-4000 PSI pressure gauge. Hold the control switch in the “raise” position. Adjust the relief valve on the side of the pump until the gauge shows 3250 PSI (FIG. 37-2). Remove gauge and reinstall pressure hose.

TERMINAL “B”BATTERY (+)

FIG. 37-1

Keep dirt, water and other contaminants from entering the hydraulic system. Before opening the hydraulic fl uid reservoir fi ller cap, drain plug and hydraulic lines, clean up contami-nants that can get in the openings. Also, protect the openings from accidental contamination during maintenance.

CAUTION

PRESSUREGAUGE RELIEF

VALVE ADJUST SCREW

(REMOVE PLUG)

FIG. 37-2


A. 90670 (800) 227-4116 FA

X (888) 771-7713

38

PLATFORM WILL NOT LOWER, LOWERS TOO SLOWLY OR TOO QUICKLY

CAUTIONKeep dirt, water and other contaminants from entering the hydraulic system. Before opening the hydraulic fl uid reservoir fi ller cap, drain plug and hydraulic lines, clean up contaminants that can get in the openings. Also, protect the openings from accidental contamination during maintenance.

NOTE: In most cases, you can avoid having to bleed the hydraulic system by correctly positioning Liftgate platform before opening hydraulic lines. Refer to following procedure. Save time on the job and prevent accidental fl uid spills and hazards.

1. Use voltmeter to verify power is being supplied to solenoid terminal “B”. Recharge the battery if volt-meter displays less than 12.6 volts (FIG. 38-1).

2. Check for structural damage or poor lubrication. Replace worn parts.

3. Check if solenoid valve is getting power by holding a screwdriver against the top nut of the solenoid. Push control switch to “lower” position to energize solenoid (FIG. 38-2). A good solenoid will attract (magnetically) the screwdriver to the nut and make it diffi cult to pull the screwdriver away from the nut.

4. Check the valve stem by removing the coil assem-bly (Item 1, FIG. 38-2). With platform supported, unscrew the valve stem (Item 2, FIG. 38-2) from the pump. Push on the plunger located inside the valve stem by inserting a small screwdriver blade in the end. If the plunger does not move freely (approxi-mately 1/8”), replace the valve stem.

6. Check and clean fl ow control valve in high pressure hydraulic line attached to cylinder.

5. Check if fi ltering screen on solenoid valve is plugged. Clean carefully if required.

2

1/8”1

FIG. 38-2

FLOW CONTROL

VALVE

VENT/DOWN PORT(REF)

RAISE PORT(REF)

FIG. 38-3

7. Check if fl ow control valve (FIG. 38-3) is pointing to the direction of restricted fl uid fl ow (back toward pump). If required, remove fl ow control valve and install it correctly (FIG. 38-3).

TERMINAL “B”BATTERY (+)

FIG. 38-1

TROUBLESHOOTING

M-16-35 REV NOVEMBER 2017 - Maxon Lift...14 Combined EXXON & MOBIL oils on the same row with updated...

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Transcript of M-16-35 REV NOVEMBER 2017 - Maxon Lift...14 Combined EXXON & MOBIL oils on the same row with updated...